hey Jake answer this please

[MuddnMason]

Got my OEM manual today, the one I asked about on HL. I am looking at getting some significant upgrades, like 424 and dgl. The 424 for instance has differing part numbers for the model years of 95-98 and 99-01? Do you think this difference is if the quads are essentially the same?

[Jake]

The difference isn't much. This is where you'd need your lawyer for the fine print.
Check out www.ronnies.com and look up your front differential. (under Frame, Final Gear-Front).

You'll see two driveshaft assemblies, number 6? and 69? (Dang, shouldn't have closed it yet)
As you scroll down, you'll see that the lower driveshaft isn't available for yours. Go back to a 95 however and you'll see that yours is pictures still, but not available.

Careful study will show you that there is virtually the same driveshaft, just fitted differently to seal out the dust.

The "good part" is just the same. Remove the diff bolts and bracket, slide the whole thing front. (You need not remove either axle shaft, as it's not being moved far), and with the differential pulled forward grab the driveshaft collar by the engine... Yeah, I know this book doesn't have an "ending" to spoil, but I'll let you read it.

You'll swear and cuss a little, but you'll get it for sure. You'll see when you get in there just how small the differences really are.

Interestingly enough, Honda doesn't "break" their driveshafts at the 98/99 break. They show the new one in the 98's as well.?? Possibly they are interchangeable, but I'd still order the 424 that Warn lists for yours.

[MuddnMason]

When I order it, I will be sure to get the right one. I was just wondering exactly what the difference was, and how many other things are just slightly different. This manual I got *should* be accurate enough for most anything I'll do, right, like service work, etc? Oh, its nice to have someone who "reads the service manuals before he goes to bed every night." ;D

[TRHOD]

Hey Phil,

The semi-lurker has something to say about this

I put a 4-2-4 on my bike earlier this spring. Here is a couple of thoughts for you.
Make sure you remove the differential bolts. You're gonna have to get the diff as far forward as possible to get the 4-2-4 shaft on. It helps to have another set of hands to do this. I had my son with a long screwdriver prying upward on the diff from the front of the bike to get maximum room to get the shaft on. This thing was a pain in the to get on. For me, at least.

MAKE SURE YOU GET THE 4-2-4 SPRING IN THE RIGHT END. Please, don't ask how I know this, but it took me forever to get it on, and then I realized I had it on backwards The spring goes in the front differential end. Then you have to compress the spring (By pushing forward on the shaft) to get the back part of the 4-2-4 shaft into the sleeve that connects to the engine.

There is a sleeve that come off the OEM shaft that you use to attach the 4-2-4 shaft to the transmission (the engine side) end. You will want to slide this sleeve over the spines of the the transmission and then put the 4-2-4 shaft into this. Again I had to use a big, long screwdriver to get enough leverage to compress the spring and get the 4-2-4 shaft into this sleeve.

DON'T TRY AND PUT THE SLEEVE ON THE 4-2-4 SHAFT AND PUT THE SLEEVE ONTO THE TRANSMISSION SPLINES. Again, don't ask But if you try and do it this way you will destroy the ruber O-ring on the splines or in the sleeve or both. You may want to get a couple of these O-rings extra before you start. There is a small one in the sleeve and a large one on the spline shaft comming from the transmission.

I applied cable-lube to the cable when I had the button assembly pulled off. When you get the instructions you will know what I mean. It was very easy to apply the cable-lube at this point. If you wait until after everything is assembled, you won't be able to apply it without some disassembly.

I think this was all the follies I had with it. It might have been that I didn't have the right tools or the right brain for this job. It might be very easy for you, or someone else, but with my pea-brain and the tools I had it did takes some time and a few obscenities.

Of course, I didn't think about this till now. If you are doing the DGL at the same time it might be a piece of cake, since you have to remove the front diff.

Anyway, good luck with your projects. I hope this helps.

By the way. I ordered my 4-2-4 for Yasky's. Aden, the guy I talk to at Yasky's, knew exactly which 4-2-4 shaft I needed.
Blessings,

[MuddnMason]

Thats what I am planning on doing, the DGL and 424 all at once. No sense in taking the diff nearly out then doing it again later on, or vice versa.

Thanks Brother.

[Jake]

Don't count on a free ride by installing both. You have to remove the front driveshaft in order to remove the front differential.

[Jake]

muddnmason said:

... how many other things are just slightly different. , like service work, etc?... ;D

I don't remember the exact year it changed, but you may find that the lower headlights mount to the plastic slightly differently, but they take the same bulb, and the service procedure will be the same.
There really aren't any differences in the servicing. Torque specs will be correct, fluid recommendations and capacities will be correct, basically it is all the same. Just extremely superficial differences, and not very many at that.

muddnmason said:

...This manual I got *should* be accurate enough for most anything I'll do, right...

No, I wouldn't say that. You seem reasonably thoughtful in your undertakings, at the very least you're a little bit mechanically inclined (and believe it or not, that's better than many highly regarded, very productive automotive technicians). I say it is more like accurate enough for anything you "could" do to the bike. The differences are extremely superficial. If you're "going in deep" working on "scary stuff" (engine, transmission, differential, rear final drive) you'll find it 100% accurate for these items.

muddnmason said:

...someone who "reads the service manuals before he goes to bed every night...

Yeah, I saw that. It seems like a lot to remember (and by NO means to I know the whole book), but most assuredly, had you found a reason to repair on your Foreman what I have found a reason to repair on mine, you'd be fixing them for your friends and telling me a thing or too about how they work as well.